Catalyst containing iron oxide, chromium oxide and a potassium compound



United States Patent Office 3,385,798 Patented May 28, 1968 3,385,798 CATALYST CONTAINING IRON OXIDE, CHROMEUM OXIDE AND A POTASSIUM COMPUUND John E. Malian, Stanley D. Turk, and Ralph P. Williams,

Bartlesvilie, Okla, assiguors to Phillips Petroleum Company, a corporation of Delaware No Drawing. Continuation-impart of application Ser. No. 859,150, Dec. 14, 1959, which is a continuation-in-part of application Ser. No. 734,424, May 12, 1958. This application Nov. 2, 1964, Ser. No. 408,403

4 Claims. (Cl. 252-470) ABSTRACT OF THE DISCLOSURE A catalyst containing 1 to 7 weight percent iron oxide, to 50 weight percent chromium oxide and to 79 weight percent of at least one potassium compound (calculated as K CO selected from the group consisting of KOH, K 0 and K CO has high selectivity in the dehydrogenation of alkylpyridines.

This is a continuation-impart of our copending application Ser. No. 859,150, filed Dec. 14, 1959, now US. Patent 3,168,524, which is a continuation-in-part of copending application Ser. No. 734,424, filed May 12, 1958, now abandoned.

This invention relates to catalysts. In one aspect the invention relates to a novel catalyst containing chromium oxide, iron oxide and a potassium compound.

In the catalytic dehydrogenation of alkylpyridines to produce alkenylpyridines the first catalytic materials developed required periodic regeneration steps to remove the coke or carbonaceous material deposited on the catalyst during the dehydrogenation reaction. Later, catalysts were developed which were partially self-regenerating when the reactant materials were admixed with steam so that the operation could be carried out in a continuous manner with only occasional regeneration, say as little as one hour for each twenty-four hours of operation.

A typical catalyst of this type is an iron oxide catalyst containing a small amount of chromium oxide as a stabilizer and a small amount of potassium compound as a promoter. While yields, i.e., mols of product produced per 100 mols of feed charged on a once-through basis, are excellent with this type of catalyst, the selectivity, i.e., mols of product produced per 100 mols of feed destroyed, while satisfactory for many purposes leaves considerable room for improvement. It will be understood that, in a commercial plant employing large quantities of material, an increase in the order of one percentage point in selectivity provides a very substantial net increase in production because this increase, instead of being converted to unwanted and unsalable by-products, is converted to the desired product. A very important advance in this direction was made by the still later development and commercial use of a catalyst containing over weight percent potassium carbonate, a small amount of chromium oxide and a large amount of iron oxide.

We have now discovered a new chromium oxide-potassium compound-iron oxide catalyst which gives even greater selectivity in the dehydrogenation of alkylpyridines, such as Z-methyl-S-ethylpyridine, to produce alkenylpyridines than any previously known catalyst. Also, when operating with the catalyst of the invention to dehydrogenate an alkylpyridine, it has been found that this higher selectivity can be obtained with relatively high per pass conversions of the starting material; moreover, although the selectivity decreases as the per pass conversion increases, this effect is less pronounced than with prior catalysts.

Broadly, the catalyst of the invention comprises a mixture of chromium oxide, iron oxide and a potassium compound, of which mixture 20 to 50 weight percent is chromium oxide, 1 to 7 weight percent is iron oxide and 45 to 79 weight percent is the potassium compound, calculated as K CO The potassium compound employed is one or more of potassium hydroxide, potassium oxide or potassium carbonate, although catalyst preparation is usually easier when making up the catalyst mixture employing potassium carbonate, and potassium carbonate is usually employed. Such catalysts are self-regenerative when employed in accordance with the invention, using steam in admixture with the feed, and in practice can be employed without burning off carbonaceous material with oxygen-containing gases during the entire life of the catalyst. Although superior catalysts are obtained in the broad range of compositions given above, it is preferred that the mixture contain from 40 to 45 weight percent chromium oxide, 50 to 55 weight percent potassium compound, and 3 to 7 weight percent iron oxide. Such catalysts not only have high selectivities at high per pass conversions and are self-regenerative but also have a long life at high activity and selectivity.

In preparing the catalyst of this invention it is advantageous to utilize an iron oxide wherein substantially all the particles have a size of two microns or less, and an average particle size of less than one micron. Usually the chromium oxide employed is substantially all of a particle size of less than 8 microns.

Numerous methods for preparing the catalyst are available. For example, the catalyst components can be brought together in a mill, such as a hammer mill, and milled to break up the agglomerates to small size, the milled mixture pelleted and dried, and the catalyst used in the dehydrogenation process. Alternatively, the catalyst components can be formed into a paste with any suitable liquid such as Water or dilute tannic acid, and extruded into any desired shape or size. Other methods involving coprecipitation, impregnation and other known methods, may also be used with satisfactory results. By whatever method the catalyst is prepared it is usually given a final heat treatment below the calcination temperature to afford a final drying for a period of from 6 to 20 hours at 1000 F. This heat treatment is preferably effected in the absence of an oxidizing atmosphere.

It will be obvious to those skilled in the art that rather than using iron oxide and chromium oxide as starting materials the metal nitrates may be used and thermally decomposed in the process of preparation of the catalyst.

In the dehydrogenation process utilizing the catalyst of the invention in the production of alkenyl-pyridines from alkylpyridines containing at least one alkyl group having at least 2 carbon atoms, the reaction is effected at high temperature and in the presence of steam. The temperature is ordinarily in the range from 1100 to 1300" F. With temperatures much below 1100 F. the conversion falls off rapidly and with temperatures much above 1300 F. the selectivity of the reaction decreases undesirably; however, the catalyst can be employed both at higher and lower temperatures than those indicated, such as for instance, at temperatures within the range from 1000 to 1400 F.

The steam diluent is ordinarily employed in the amount of 2 to 15 parts by weight per part of alkylpyridine charged, usually between 4 and 10 parts by weight per part of alkylpyridine. It is advantageous to maintain a pressure as low as feasible and pressures within the range from 14.7 to 25 p.s.i.a. are ordinarily utilized. However, elevated pressures are operable. During the conversion, the flow rate of the alkylpyridine feed vapors, expressed as liquid hourly spaced velocity, that is, liquid volume of alkylpyridine charged per volume of catalyst per hour, is generally in the range between 0.5 and 5.

The catalyst of this invention is applicable to the dehydrogenation of alkylpyridines where at least one alkyl group is present which contains at least two adjacent carbon atoms, each having an attached hydrogen atom. Di-, tri-, and tetraalkylpyridines can be dehydrogenated with the alkyl substituents being present in various positions on the pyridine nucleus, for instance, 2,4-diisopropyl-6- ethylpyridine and 2,3,4,6-tetraethylpyridine. It is understood that the alkenylpyridines produced can contain one or more alkenyl or vinyl groups and also one or more alkyl groups, particularly the methyl group. The invention is most advantageously applicable to alkylpyridines of the foregoing description having one to four alkyl groups and having from 2 to 8 total carbon atoms in the alkyl groups, no one alkyl group Containing more than 5 carbon atoms. Besides the commercially important 2- methyl-S-ethylpyridine, other examples of the technically important group of alkylpyridines having only one or two alkyl groups which can be dehy-drogenated according to the present process are 2-ethyl-4-ethylpyridine, 3-isopropylpyridine, 2-ethylpyridine, 2-ethyl-5-ethylpyridine, 2-methyl-4-isobutylpyridine, 3-ethylpyridine, 3-n-propylpyridine, 2-isopropyl-4-(3-methylbutyl) pyridine, Z-nbutylpyridine, Z-n-amylpyridine, and 3-n-amylpyridine.

The examples which follow are illustrative of the invention only, and are not to be construed to limit the scope of the invention.

In Examples I through III, which follow, the catalyst of the invention designated as A was prepared in the following manner.

The following ingredients were dry blended in the preparation of the catalyst:

Grams K CO 1 208.8 C5 171.2 F2O33 glBaker and Adamson, Reagent Grade, anhydrous, lot M- -".T. T. Bakers C.P., lot 7582. 97 percent 5 microns or less in diameter.

a C. K. Williams, 110-3097, Kroma Red Series. At least 99.0 percent of the particles 1 micron or less in diameter.

The potassium carbonate was hammer milled inch screen on hammer mill) prior to dry blending it with the other ingredients. A small amount of graphite was included in the composition as a lubricant. The ingredients were dry blended and inch diameter tablets, or slugs, were prepared on a Stokes BB-Z pilling machine at 65 pounds pressure. The slugs were ground in a Foley food mill after which the particles were rubbed through a 20 mesh screen and the resulting powder was then sieved to a to 100 mesh size. Water (10 weight percent of the 35400 mesh powder) and a small additional amount of graphite were blended with the powdered material and the blend was sieved to a 35-100 mesh size. Pellets inch in diameter and inch long were prepared from the catalyst mixture using a Stokes BB-Z pilling machine. A crushing strength test was made. The average crushing strength of pills was 6.9 pounds (total force).

The catalyst was thereafter heated in an oven at 110 C. for 72 hours. It was then put in place in a vertical reactor comprising a pipe approximately 5 feet long and having an inside diameter of 1 inch. Electrical resistance heaters were placed at intervals throughout the length of the reactor. The catalyst was supported on Berl saddles which are previously crushed and screened to 3.55 mesh. About 4 inches of the crushed Berl saddles were charged, then cc. of the catalyst, and then more Berl saddles to fill the remaining portion of the reactor to within about 1 inch of the top.

The catalyst was thereafter given a final drying treatment by heating it slowly in place in the reactor to 1000 F. at a rate less than 150 F. per hour. Nitrogen was passed over the catalyst during the heating period at a rate of about cc. per minute. The time of this heating was 7 hours and 10 minutes. The temperature was then maintained at 900-1000 F. for 15 hours during which time the passage of nitrogen gas over the catalyst was continued.

In Examples I through III two prior art catalysts designated as B and C were similarly placed in reactors for the purpose of making the comparative runs set forth in these examples. The three catalysts are set forth in Table I below which shows the parts by weight of each of the active ingredients of the respective catalysts.

To obtain the results shown in Examples I through III, each of the reactors containing catalysts A, B and C, respectively, were run continuously during the day time for a period of from about 4 to 6 hours each day under reaction conditions while charging the Z-methyl-S-ethylpyridine with steam as feed to the reactors. Once or twice a day quantitative runs would be made, usually of 1 hour each. That is, the raction products were carefully collected and analyzed during these periods to obtain the data, while the rest of the time during the day the product was discarded. Near the end of the day the flow of Z-methyI-S-ethylpyridine was discontinued and that which remained in the reactor was flushed out by passing steam through the reactor for 30 minutes at the reaction temperature. The steam was shut oil and the catalyst was allowed to cool to about 1000 F. while nitrogen was bcing passed over it. The flow of nitrogen was continued overnight with the temperature being maintained at about 1000 F. In preparation for another days operation, the temperature was increased to at least 1100 F. at which time the fiow of nitrogen was discontinued and steam was passed through the reactor for 15 to 30 minutes before 2-methyl-5-ethylpyridine was introduced together with steam. The temperature was adjusted at the operating level and operation was continued for the remainder of the day. Occasionally, a quantitative test was made of 6 hours duration, and the results from these runs are shown in Example III.

The periods of steaming the catalyst without introducing feed material to be dehydrogenated are unnecessary in commerical operations, but were employed in these tests in order to flush out the nitrogen and raise the reaction temperature before the introduction of feed.

Reaction conditions were varied from day to day for the collection of samples under different conditions. The results shown in Examples I through III show the time at which each quantitative run Was made, as indicated by the catalyst age in hours. In the tables the term catalyst age means the total time that the charge stock has been passed over the catalyst before the beginning of the quantitative run, and does not take into account the steaming periods or the periods of flushing with nitrogen.

The method of conducting the tests in Examples I through III was as follows: liquid 2 methyl-S-ethylpyridine, contained in a graduated reservoir, and water, also contained in a graduated reservoir, were pumped continu ously and simultaneously through two micro-bellows pumps. The Z-methyl-S-ethylpyridine was passed directly to the top of the reactor where it was vaporized. The water was pumped through a preheater where it was heated to 600700 F. and then passed to the top of the reactor where it was mixed with vaporized 2-methyl5- ethylpyridine. The Z-methyl-S-ethylpyridine space velocity used in these examples was 1.8 volumes/volume catalyst/ hour which corresponded to a pumping rate of about 90 cc./ hour. The steam to Z-methyl 5 ethylpyridine weight ratio was maintained at about 6:1 which corresponded to 490-500 cc. water pumped per hour.

Gases were passed from the bottom of the reactor to a water-cooled condenser where normally liquid products were condensed and then collected in a receiver. 011 gas was passed through another water-cooled condenser and then through a Dry Ice trap and finally through a wet test meter. Most of the liquid materials contained in the off gas were collected in the Dry Ice trap and were then added to the liquid products previously collected.

The liquid portion of the reactor eifiuent obtained in the quantitative run contained both aqueous and oil phases which were separated. In the runs of Examples I and II, the aqueous phase was saturated with potassium carbonate to salt out any dissolved alkylpyridines. The oil phase which was separated was added to the original oil phase. The combined oil phase was then saturated with potassium carbonate and the water contained in it was separated and the oil recovered was weighed. It was submitted for a mass spectrometer analysis and found to contain 3- ethylpyridine, Z-picoline, 3-pic0line, 3-vinylpyridine, 2,5- lutidine, Z-methyl 5 vinylpyn'dine, and unreacted 2- methyl-S-ethylpyridine. In the 6 hour runs of Example III, the liquid portion of the reactor etfiuent contained a larger volume of water than the runs of Examples I and 11. After separation of the aqueous and oil phases, the aqueous phase was distilled, about 500 cc. being taken 6 The Z-methyl-S-vinylpyridine (MVP) per pass yield, MVP selectivity, and Z-methyl-S-ethylpyridine (MEP) conversion were calculated in the following manner:

Mols MVP obtained 5 Mols MEP charge Mols MVP obtained Mols MEP consumed MVP per pass yield MVP selectivity It can be seen from the foregoing data that the MVP selectivities from the runs using the catalyst of the invention are much higher than those from the runs using catalyst B and C, and that the higher selectivities are obtained even though the MEP conversion is higher with catalyst A than with catalyst B. Although the conversion employed in the runs with catalyst C was higher than the conversion was carried with catalyst A, it will be seen that the conversion of run 6 was only 1 percent higher than run 1 while the selectivity was 16.7 points lower. The following Example II, moreover, makes it clear that the slightly lower conversion with catalyst A shown in Table II does not account for its greatly increased selectivity over catalyst C shown in Table II.

EXAMPLE II One-hour runs were made with each of catalyst A, B, and C. Results are set forth in Table III.

(100%)=MVP per pass yield (100%) MVP selectivity (ultimate yield) 10 (100%) =MEP converstion overhead. The residue was discarded. The distillate was combined with the original oil phase and the two phases were separated. The aqueous phase was treated with potassium carbonate and the remainder of the procedure was the same as for the run of Examples I and II. This method requires less potassium carbonate than would be needed if the entire aqueous phase were treated.

The mass spectrometer takes no account of water present. A 25 gram sample of the oil phase was analyzed for water by adding cc. of toluene, azeotroping out the water, collecting it in a trap, and measuring it. From the weight of original oil analyzed and the amount of water found, the quantity of dry oil was calculated. The spectrometer analysis was applied to the dry oil for calculation of the amount of each material present.

These data show that with the increase in temperature a higher per pass yield is obtained together with a higher conversion, and yet the selectivity remains very high with catalyst A of the invention. In comparison prior art catalyst B and C at about the same MEP conversion, or lower, have much lower selectivities. This example, and the other examples herein show the relative insensitiveness of the MVP selectivity over a wide range of MEP conversions, a decided advantage in commercial operation.

EXAMPLE 111 Two six-hour runs were made using catalyst composition A and one six-hour run was made using catalyst composition B and one six-hour run using catalyst C. Results of these runs are set forth in Table IV.

TABLE IV Cat- Catalyst Temperature, MVP Yield, Mol percent MEP Run No alyst Age, F. Conversion,

Hours Per Pass Selectivity percent EXAMPLE I Results of two runs each using catalyst A, B, and C are shown below in Table II.

These runs illustrate in a longer run the relatively very high selectivity of the catalyst composition A of the invention compared to the prior art. Run 2 is particularly G5 noteworthy in that even at the very high MEP conversion of 80.5 percent, the MVP selectivity was maintained at 80 percent.

EXAMPLE VI To show that the excellent results obtained in the EXAMPLE V shorter runs of.Examp.les I i H can g g Another batch of catalyst of the invention was prepared over a long period of a h 6 test was S out Wit using the same ingredients as catalyst A except that the catalyst A For comparative purposes a hie test was also chromium id was igment grade chromic oxide; 97% effected with catalyst B. The runs were effected under the of the chromium Oxide had a particle Size of 4 or less in Same conhmohs descnbedhs to h rate Space velocity diameter. The pills were prepared in the same manner as sleam as dhschhed i resiject to Examhles described with respect to catalyst A except that no water I but run was chntmuous y on conyerslon was added and the pills had an average crushing strength without interruptlon for a period of 46 days. Durmg the of pins of 76 pounds (total force). period the temperature was varied to obtain various de- This Catalyst was supported on Berl saddles in the grees of conversifm of the For these life tests the 1:- reactor described before and cc. were charged to the reactor was mod1fied to use line steam so that the water 0 reactor in the same manner Prior to charging the catalyst reservolh pump and prhheater were ehhhhated' it was heated in an oven at 110 C. for hours. While hueht washhhlyzed at hhhrvals and the length P h in place in the reactor, this catalyst was also heated slowduring WhlCh the sample was taken for analysls is given 1y to 10000 F. at a rate less than F perhoun Nim} lh h hght hand chhhhh 9 Table Whlch fohOWS- h gen was passed over the catalyst during the heating period actlon temperature in the l1fe test using catalyst A varled at a rate of approximately 90 cc per minute The time throughout the 46 hh h 1150 to 129,40 h the taken for heating to 1000 F. was 6 hours and 15 minutes. temphrathrhs prhvalhhg dhnhg the samphhg porhohsof The temperature was then maintained at 9001000 F. the tests belng given 1n Table V. Checks ofthe operation for 15 hours d i hi h time the passage of nitrogen duhhg the first hh days wlth h i A mdlcated that 25 over the catalyst was continued. Z-methyl-S-ethylpyridine the MVl? select1v1ty was improving with age. Complete was dehydmgenated employing this catalyst using a Space f begmnmg on the tenth day and Spaced over a P velocity of the MEP of 1.8 volumes/volume catalyst/ 9 R 2 days are shown on two hour l f h hour and a steam of MEP weight ratio of 6 to l, a preshhs E" 10d Cata1YSt A Table V F Whlle slmllar sure a little above atmospheric and a temperature of 1152 dam 13 Shown beglnnlng Wlth the ninth y for 30 to 1155 F. After 3 days of continuous operation the y product was collected over a period of two hours and TABLE v MVP Yields, M01 percent MEI Duration Catalyst Age, Days Temp, I Conv. or Run,

Per Pass Selectivity Percent Hours Catalyst A:

It will be seen that the life test with catalyst A is in general even superior to the tests of catalyst A shown in Examples I through III, in which the catalyst age under conversion conditions was shorter. The life test with catalyst A compares quite favorably with the test of catalyst B, as is apparent from the data.

In the last four runs in the life test of catalyst A, the temperature was raised higher than normally would be done at this age of the catalyst in order to see the effect of the high MEP conversions on selectivity. It will be noted that the selectivities were maintained quite high even at the high temperatures and high conversions which were maintained throughout the last eleven days of the test. The data indicate a possible trend during the last eleven days toward a gradual lessening of the activity of the catalyst during the period where the unusually high conversions were maintained. In normal operation the temperatures would not usually be raised this high while the catalyst was still so active since it would usually be preferred to take advantage of the higher selectivities at somewhat lower conversion. However, if it were desired in operation to obtain as high a production as possible in a given plant, the high conversions could be taken analyzed. It was found that an MEP conversion of 39.7 had been obtained with a per pass yield of MVP of 35.8 and an MVP selectivity of 90.3.

EXAMPLE VI In this example, comparative dehydrogenation runs were carried out using the three catalyst compositions set forth in Table VI.

TABLE VI Catalyst CI203 K2003 F0203 D 42. 57. 2 0 E 45. 0 53. 0 2. 0 F 42. 8 52. 2 5. 0

After drying the 35-100 mesh catalyst powder was heated in an air oven at 470 to 485 F. for 6 to 7 hours, 0.5

ethylpyridine under the same conditions. Results are shown in Table IX.

TABLE IX Catalyst 1 MVP Yield, Mol Percent MEP Run No. Cat- Catalyst Temp., F. Conversion,

alyst ge, Percent Days Top Bottom Per Pass Selectivity 1 Average of temperature readings taken at 15 minute intervals.

percent of graphite was added and the mixture was formed into /8-111611 catalyst tablets on the BB-2 machine.

These catalysts were employed in the dehydrogenation of Z-methyl-S-ethylpyridine (MEP), the catalysts being in fixed beds in the tubular reactor employed. The reactors were operated continuously at an MEP space velocity of 1.8 volumes/volume/hour using a weight ratio of steam to MEP of about 6: 1.

Table VII below shows the age of the catalyst when the quantitative data was taken. Each period of data taking in Runs 14 and 8-11 Was over a two-hour period of operation, and each period of data taking in Runs 5-7 was over a four-hour period of operation. The results are shown in Table V11.

The data in Table 1X show that Catalysts G and H of this invention also give much higher selectivities at higher conversions than that of Catalyst 1 which contains a higher percentage of Cr O than that within the scope of this invention.

As will be evident to those skilled in the art, various modifications of this invention can be made or followed in the light of the foregoing disclosure and discussion without departing from the spirit or scope of the disclosure or from the scope of the claims.

We claim:

1. A catalyst composed of the following as essential active ingredients: 3 to 7 Weight percent iron oxide, to weight percent chromium oxide and to Weight percent of at least one potassium compound, calcu- TABLE VII Catalyst 1 MVP Yield, Mol Percent MEP Run No Cat- Catalyst Temp., F. Conversion,

alyst ge, Percent Days Top Bottom Per Pass Seleot1v1ty 1 Average of temperature readings taken at 15 minute intervals.

The data in Table VII show that Catalysts E and F of this invention give much higher selectivities at higher conversions than that of Catalyst D which contains no iron oxide and is outside the scope of this invention. At equal conversions the difference in selectivity would be even greater since higher conversions result in lower selectivity with a given catalyst; this is brought out, for instance, by comparing Run 10 with Run 11. Also, note the lowering of selectivity of Catalyst D when its conversion is raised to 35.2, as in Run 4.

EXAMPLE VII In this example, comparative dehydrogenation runs were carried out using the three catalyst compositions set forth in Table VIII.

TABLE VIII Weight Percent Catalyst GU03 K2003 FezOs and were employed in the dehydrogenation of Z-methyl-S- lated as K CO selected from the group consisting of KOH, and K2CO3.

2. A catalyst composed of the following as essential active ingredients: 42.8 weight percent chromium oxide, 5 weight percent iron oxide and 52.2 weight percent K 00 3. A catalyst composed of the following as essential active ingredients: 45 Weight percent chromium oxide, 2 weight percent iron oxide and 53 weight percent K CO 4. A catalyst composed of the following as essential active ingredients: 25 weight percent chromium oxide, 5 weight percent iron oxide and Weight percent K CO References Cited UNITED STATES PATENTS 2,408,140 9/ 1946 Gutzeit 252-470 2,683,123 7/1954 Schwegler et a1 252-470 2,769,811 11/ 1956 Mahan 252-474 2,775,637 12/1956 Lanning et al. 252-474 DANIEL E. WYMAN, Primary Examiner.

P. E. KONOPKA, Assistant Examiner. 

